installation manual eh99865401.pdf

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Installation manualAir conditioner(Split type) 1 English

AIR CONDITIONER (SPLIT TYPE)

Outdoor Unit

Model name:

RAV-SP240AT2-UL

Manuel d'installationClimatiseur(Type split) 23 Franais

Installation manual

For OUTDOOR USE only

Not accessible to the general public

Vente interdite au grand public

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Outdoor Unit Installation Manual

1 DIMENSION

3.0"(75)

2.8"(70)

15.0"(380)

1.8"(46)

6.7"(170)

4.7"(118)

15.1"(383)2.9"(74)

5.0"(128)

5-drain hole

0.8"(20) ~ 3.5"(88)

burring hole

A legs

23.6"(600)5.9"(150)

B legs2.4"(60)7.9"(200)

1.6"(40)

Details of A legs

0.7"

(17.5)

14.4"(365)

0.7"(17.5)

2.1"(54)

1.9"(48)

1.5"(39)

3.8"(96)

1.2"(30)

9.7"(247)

10.0"(255)

7"(178) 7" (178)2.4"(60)

2.7"(68) 20.4"(518)

7"(178)

12.9"(327)

21.0"(534)

22.9"(581)

5.8"(148)

6.5"(165)

35.4"(900) 12.6"(320)

35.0"(890)

15.7"(400)

3.4"(85)

2.0"(50)

2.2"(56)

5.1"(130)

0.7"(18) 2.3"(58)

3.9"(99)

Conduit hole( 0.9"(22) hole)

Drain hole

( 1.0"(25) burring hole)

1.3"(34)Air inlet

port

Air inletport

Air outletport

Mounting hole sold separately

(12 - 0.1"(3) emboss)

Refrigerant pipeconnecting port

0.4"(9.5) flareat liquid side

Refrigerant pipeconnecting port

0.6"(15.9) flareat gas side

0.3"(7)3.3"(83)

2.6"(65)

0.3"(7)

Z views

Z

Knockout for downward piping

Refrigerant piping hole

( 0.5"(12) ~ 0.7"(17) long hole)Mounting bolt hole

1.0"(24)

21.7"(550)2.0"(52)

1.6"(40)

0.5"(12)

Details of B legs

( 0.5"(12) ~ 0.7"(17) U-shape hole)Mounting bolt hole

Refrigerantpiping hole

3.7"(95)

2.2"(55)

0.5"(12) 2.5"(64)

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3 SYSTEM REQUIREMENTSPiping (Field supplied) Minimum refrigerant line length between the outdoor

unit and indoor unit is 16.5 (5 m)

Maximum pipe lengths

Figure of Single

Refrigerant sizes

Flare nuts and flaring

The flare nuts and flaring are different from those for

the conventional refrigerant.

Use the flare nuts supplied with the air conditioner or

those for R410A.

Before performing flaring, carefully read

REFRIGERANT PIPING

Insulation

Both lines need to be insulated. Use a minimum 0.4

(10 mm) wall thickness.

Refrigerant charge

* Caution during addition of refrigerantMax. amount of additional refrigerant is 1.8 lbs (800g).Charge the refrigerant accurately. Overcharging

may cause serious trouble with the compressor.* Minimum refrigerant pipe is 165(5 m).

This may cause a malfunction of the compressor orother devices.

Metering Device is an electronic EXV (PMV) inoutdoor unit.

Connecting power and controlcables (Field supplied)

The main power is supplied to the outdoor unit. The

field supplied connecting cables from the outdoor

unit to the indoor unit consist for 4 wires and provides

the power for the indoor unit as well as the

communication signal between the outdoor and

indoor unit.

System interconnection wire size must be AWG12.

Breaker must have a capacity specified in the

following table.

All wiring must comply with local electric codes and

NEC (National Electric Code) or CEC (Canadian

Electric Code).

Allowablepipe length

(ft (m))

Height difference(Indoor-outdoor H)

(ft (m))

Number ofbent portions

Total lengthL

Indoor unit:Upper

Outdoor unit:Lower 10 or less

1641 (50) 985 (30) 985 (30)

Liquid side Gas side

Outerdiameter

ThicknessOuter

diameterThickness

3/8(9.5 mm)

0.03(0.8 mm)

5/8(15.9 mm)

0.04(1.0 mm)

HL

Indoor Unit

Outdoor Unit

Length of refrigerantpipe connected to

indoor/outdoor unitAdditional refrigerant

165 - 985(5 - 30 m)

None

*985 - 1641(30 - 50 m)

Add 0.43 oz/ft (40 g/m) ofrefrigerant for piping that exceeds985 (30 m) up to 1641 (50 m).

Model RAV- SP240

Power supply 208/230 V, 60 Hz

MCA 24 A

MOCP (MAX Fuse/CB) 40 A

Breaker 25 A

System interconnection wires AWG12

MCA = Minimum Circuit AmpsMOCP =Maximum Over Protection Device Amps.

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4 PRECAUTIONS FOR SAFETYInstalling, starting up, and servicing air--conditioning equipment can be hazardous due to system pressures,

electrical components, and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service mechanics should install, start--up, and service this equipment.Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should

be performed by trained service personnel.

When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached

to the equipment.

Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher nearby

when brazing. Use care in handling, rigging, and setting bulky equipment.

Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the

unit. Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety

information. This is the safety--alert symbol . When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury.Understand these signal words: DANGER, WARNING, and

CAUTION. These words are used with the safety--alert symbol.

DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNINGsignifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which

may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which

will result in enhanced installation, reliability, or operation.

WARNING

Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner.Perform installation work properly according to the Installation Manual.Inappropriate installation may result in water leakage, electric shock or fire.

Be sure to ground the equipmentImproper grounding may cause an electric shock.Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone wires.

Turn off the main power supply switch or breaker before attempting any electrical work and maintenance.Make sure all power switches are off. Failure to do so may cause electric shock.Use an exclusive power circuit for the air conditioner. Use the rated voltage.

When moving the air conditioner for installation to another place, be very careful not to allow the specifiedrefrigerant (R410A) to become mixed with any other gaseous body into the refrigeration cycle.If air or any other gas mixes with the refrigerant, the gas pressure in the refrigeration cycle will become abnormallyhigh and it may result in the pipe bursting or personal injuries.

Do not modify this unit by removing any of the safety guards or by by-passing any of the safety interlockswitches.

Do not touch the intake or aluminium fins of the outdoor unit.Doing so may result in injury.

Tighten the flare nut with a torque wrench in the specified manner.Excessive tightening of the flare nut may cause a crack in the flare nut after a long period, which may result inrefrigerant leakage.

Install the air conditioner securely in a location where the base can sustain the weight of the unit adequately.

If refrigerant gas has leaked during the installation work, ventilate the room immediately.If the leaked refrigerant gas comes in contact with fire, noxious gas may be generated.

After the installation work, confirm that refrigerant gas does not leak.If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may begenerated.

Electrical work must be performed by a qualified electrician in accordance with the NEC or local code. Makesure the air conditioner uses an exclusive power supply.An insufficient power supply capacity or inappropriate installation may cause fire.

Use only the specified wiring during the unit installation. Ensure that all terminals are securely fixed, so

preventing any external forces having a negative effect on the terminals.

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WARNING

When the air conditioner cannot cool or heat a room well, contact the dealer from whom you purchased theair conditioner as refrigerant leakage is considered as the cause.

In the case of repair that requires refill of refrigerant, ask service personnel about details of the repair.The refrigerant used in the air conditioner is harmless.Generally, the refrigerant does not leak. However, if the refrigerant leaks in a room and a heater or stove burner inthe room catches fire, it may generate toxic gas.When you ask service personnel for repairing refrigerant leakage, confirm that the leakage portion has beencompletely repaired.

Do not install the air conditioner in a location that may be subjected to a risk of exposure to a combustiblegas.If a combustible gas leaks and becomes concentrated around the unit, a fire may occur.

Install the refrigerant pipe securely during the installation work before operating the air conditioner.If the compressor is operated with the valve open and without the refrigerant pipe, the compressor sucks air and therefrigeration cycle is over pressurized, which may cause a burst or injury.

When carrying out the pump-down work, shut down the compressor before disconnecting the refrigerantpipe.Disconnecting the refrigerant pipe with the service valve left open and with the compressor still operating will causeair, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possiblyresulting in rupturing, injury, etc.

CAUTION

Do not climb onto or place objects on top of the outdoor unit.You may fall or the objects may fall off of the outdoor unit and result in injury.

Wear heavy gloves during the installation work to avoid injury.

EQUIPMENT DAMAGE HAZARDFailure to follow this caution may result in equipment damage or improper operation.

Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must bea 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length isburied, refrigerant may migrate to the cooler buried section during extended periods of system shutdown. This causesrefrigerant slugging and could possibly damage the compressor at start-up.

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5 INSTALLATION OF NEW REFRIGERANTAIR CONDITIONER

CAUTION

New Refrigerant Air Conditioner Installation THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY

OZONE LAYER.R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the workingpressure of R410A refrigerant is approx. 1.6 times as that of refrigerant R22. Accompanied with the adoption of the newrefrigerant, the refrigerant oil has also been changed. Therefore, during installation work, be sure that water, dust,former refrigerant, or refrigerant oil does not enter the new type refrigerant R410A air conditioner cycle.To prevent mixing of refrigerant or refrigerant oil, the sizes of connecting sections of charging port on main unit andinstallation tools are different from those of the conventional refrigerant units. Accordingly, special tools are required forthe new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittingsmade for R410A only, so that water and/or dust does not enter.

Required Tools/Equipment and Precautions for UsePrepare the tools and equipment listed in the following table before starting the installation work.

: R410A exclusive

: Generic

Tools/equipment Use

Manifold gauge* Vacuuming/charging refrigerantand operation checkCharging hose

Gas leak detector Gas leak check

Vacuum pump with backflowprevention function

Vacuum drying

Flare tool Flare machining of pipes Usable if dimensions are adjusted.

Bender Bending pipes

Refrigerant recovery equipment Refrigerant recovery

Torque wrench Tightening flare nuts 1/2 (12.7 mm) and 5/8 (15.9 mm)

Pipe cutter Cutting pipes

Brazing torch and nitrogencylinder

Braze pipes

Refrigerant charging scales Charging refrigerant

4 mm hexagon wrench Opening liquid valve

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Installation Location

WARNING

Install the outdoor unit in a location that can supportthe weight of the outdoor unit.Insufficient durability may cause the outdoor unit to fall,which may result in injury.

CAUTION

Do not install the outdoor unit in a location that issubject to combustible gas leaks.Accumulation of combustible gas around the outdoorunit may cause a fire.

Install the outdoor unit in a location that meets thefollowing conditions. A well-ventilated location free from obstacles near the

air inlets and air outlet A location that does not increase the operating noise

or vibration of the outdoor unit A location that does not produce any drainage

problems from discharged water Location with easy access to power.

Do not install the outdoor unit in the followinglocation. A location with a saline atmosphere (coastal area) or

one that is full of sulfide gas (hot-spring area) (Special

maintenance is required.) A location subject to oil, vapor, oily smoke, orcorrosive gases

A location in which organic solvent is used A location where high-frequency equipment (including

inverter equipment, private power generator, medicalequipment, and communication equipment) is used(Installation in such a location may cause malfunctionof the air conditioner, abnormal control or problemsdue to noise from such equipment.)

A location in which the discharged air of the outdoorunit blows against the window of a neighboring house

A location where the operating noise of the outdoorunit is transmitted

When the outdoor unit is installed in an elevatedposition, be sure to secure its feet.

A location in which drain water poses any problems.

When an outdoor unit is installed in a location that isalways exposed to strong winds like a coast or onthe high stories of a building, one of the following isrecommended. Install the unit so that its discharge faces the wall of

the structure.Keep a distance 19.7 (500 mm) or more between theunit and wall.

Install the unit so that the discharge is at a right anglerelative to the wind direction.

Use wind baffle. Produce those parts in the field. When outside temperature conditions are 23 F (-5

C) or lower and unit is running in cooling mode.

19.7" (500 mm)

Strong wind

Strong wind

Wind baffle

Wind baffle

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Barriers in front and back of unit

Open above and to the right and left of the unit.

The height of an barrier in both the front and rear of the

unit, should be lower than the height of the outdoor

unit.

Standard installation1. Single unit installation

2. Multiple unit installation

a. Intake and supply parallel

b. Intake and supply in line

Open above and to the right and left of the unit.

The height of an obstacle in both the front and

rear of the unit should be lower than the height

of the outdoor unit.

Standard installation

Installation of Outdoor Unit Before installation, check the strength and horizontal

of the base so that abnormal sounds do not

emanate.

According to the following base diagram, fix the base

firmly with the anchor bolts.

(Anchor bolt, nut: 3/8 (M10) x 4 pairs)

1) Field fabricate a snow or an ice stand for the

unit using the above dimension.

2) Place snow or ice stand on a foundation/pad

and secure it to the foundation/pad and secure

it to the foundation/pad by anchor bolts.

5.9

(150)

ormore

39

.4(1000)

or

more

11.8 (300) or more

11.8 (300)

or more

39.4

(1000)

ormore

7.9

(200)

ormore

39.4(1000)or more

11.8(300) ormore

59.1(1500)or more

78.7(2000)or more

7.9(200)or more

Drain hole

Drainnipple mounting hole

Drain hole

5.9 (150)20.7 (525)

1.8 (45)

23.6 (600)

15.8

(400)

14.4

(365)

5.9 (150)

NOTE

When the outdoor unit is anchored directly on

the foundation/pad (cooling only protrude a

minimum of 6 (15 mm)).

0.6 (15 mm) or less

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3) Place unit on stand. Make sure it is level and

fasten securely to the stand.

As shown in the figure below, install the

foundation and vibration-proof rubber pads to

directly support the bottom surface of the fixing

leg that is in contact with the bottom plate of the

outdoor unit.

When installing the foundation for an outdoor

unit with downward piping, consider the piping

work.

When water is to be drained through the drain hose,

attach the following drain nipple and waterproof

rubber cap, and use the drain hose (Inner diameter:

0.6 (16 mm)) sold on the market. Also seal the

screws securely with silicone material, etc., to

prevent water from leaking.

Some conditions may cause condensation or

dripping of water.

When collectively draining discharged water

completely, use a drain pan.

For ReferenceIf a heating operation is to be continuously performed

for a long time under the condition that the outdoor

temperature is 32 F (0 C) or lower, draining defrosted

water may be difficult due to the bottom plate freezing,

resulting in trouble with the cabinet or fan.

GOOD

Mounting leg

Foundation

GOOD

NO GOOD

Foundation

Foundation

If only the end of themounting leg issupported, it maydeform.

Do not supportthe outdoor unitonly with themounting leg.

Bottom plateof outdoor unit

Support the bottom surface of themounting leg that is in contact withand underneath the bottom plate ofthe outdoor unit.

Drain nippleWaterproof rubber cap(5pcs.)

Waterproof rubber cap

Drain nipple

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6 REFRIGERANT PIPINGPiping connections are inside the front panel of the unit

and the front panel and pipe cover needs to be

removed before piping and wiring connections aremade.

Piping can enter the outdoor unit from the back, from

the side or from the bottom as shown

1. Remove the front panel of the unit.

2. Remove the pipe cover.

3. Remove the appropriate knockout dependingon the orientation of the piping.

* Be sure to wear heavy work gloves while working.4. Remove the burrs from the knockout opening

and use the factory supplied protective edgeguard material around the opening to protect thepiping and the wiring.

5. Remove the flare nut from the service valve onoutdoor unit. Insert the flare nut into the fieldpiping, and flare the pipe.Bend the pipe approx. 90 degree with a pipebender for side and rear piping.

6. When the piping connections are complete re-install the pipe cover.

Flaring

1. Cut the pipe with a pipe cutter.

Be sure to remove burrs that may cause a gasleak.

2. Insert the supplied flare nut into the pipe, and then

flare the pipe.

As the flaring sizes of R410A differ from those of

refrigerant R22, the flare tools newly manufactured

for R410A are recommended.

However, the conventional tools

can be used by adjusting the

projection margin of the copper

pipe.

Projection margin in flaring : B (Unit : in (mm))Rigid (Clutch type)

Flaring diameter size : A (Unit : in (mm))

* In case of flaring for R410A with theconventional flare tool, pull the tool outapprox. 0.02 (0.5 mm) more than that forR22 to adjust it to the specified flare size.The copper pipe gauge is useful foradjusting the projection margin size.

Rearward

Pipe cover

Sideward

Downward

Rear

Front panel

Side

Bottom

Pipe cover

The pipe cover is easily mounted by cutting off

the slit at the lower part of the pipe cover.

Outer diameter ofcopper pipe

R410A toolused

Conventionaltool used

R410A0.04 - 0.06(1.0 - 1.5)

3/8 (9.5)0 - 0.02 (0 - 0.5)

5/8 (15.9)

Outer diameter of copper pipe A

3/8 (9.5) 0.52 (13.2)

5/8 (15.9) 0.78 (19.7)

B

+0-0.02" (0.4)

A

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Tightening of FlareConnections

1. Align the centers of the flare connections and fully

tighten the flare nuts with your fingers.

2. Use two wrenches to loosen or tighten the flare nut

on the gas service valve as shown in the figure.

Use only one wrench to loosen or tighten the flare

not on the liquid service valve.

The final tightening with a torque wrench should be

to the specifications shown in table below.

Unit : ftlbs (Nm)

After the installation work, be sure to check for gasleaks of the pipe connections with nitrogen.

CAUTION

1. Do not put the crescent wrench on the chargeorifice or cover.The valve may be broken.

2. If applying excessive torque, the nut may breakaccording to some installation conditions.

Pressure of R410A is higher than that of R22

(Approx. 1.6 times).

Therefore, using a torque wrench, tighten the flare

pipe connecting sections that connect the indoor/

outdoor units at the specified tightening torque.

Incomplete connections may cause not only a gas

leak, but also trouble with the refrigeration cycle.

Outer diameter of copper pipe Tightening torque

3/8 (9.5 mm) 24 - 31 (33 - 42)

5/8 (15.9 mm) 50 - 60 (68 - 82)

Flare nut

Loosened

Tightened

Piping valve

Cap

Valve at liquid side

Cover

Piping valveCap

Tightened

Flare nut

Loosened

Valve at gas side

Charge orifice

Do not apply refrigerant oil to the flared

surface.

Cover

NO GOOD

Charge orifice

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7 ELECTRICAL CONNECTIONSWARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result inpersonal injury or death. The unit cabinet must have an uninterrupted or

unbroken ground to minimize personal injury if anelectrical fault should occur. The ground may consistof electrical wire or metal conduit when installed inaccordance with existing electrical codes.

Before performing service or maintenance, be suremain power switch is turned OFF.

CAUTION

All wiring and connections must comply with NEC, CEC,local codes.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damageor improper operation. Unit failure as a result of operation on improper line

voltage or excessive phase imbalance constitutesabuse and may cause damage to electricalcomponents.

Wrong wiring may cause a burn-out of some electricalparts.

Do not damage or scratch the conductive core or innerinsulator of the power and inter-connecting wireswhen peeling them.

Field wiringThe dashed lines show field wiring.

System interconnection wire size must be AWG12.

Breaker must have a capacity specified in the

following table.

All wiring must comply with local electric codes and

NEC (National Electric Code) or CEC (Canadian

Electric Code).

Connect the system interconnection wires (indoor to

outdoor) to the identical terminal numbers on the

terminal block of each unit.

Incorrect connection may cause a failure.

1. With the front panel removed the electrical control

box is exposed at the top right corner of the unit.

2. Terminate the field wiring conduit (if used) at the

conduit connection holes provided.

3. Route the field power wires and the systeminterconnection wires as shown on the following

pages. Terminate the wires at field wiring terminal

blocks located immediately below the electrical

control box.

Electric parts box

Conduit connection

holes

Piping knockoutPipe cover

Front pane

Electric control box

Field wiringterminalblocks

Conduit connectionholes

Front panel

Piping knockoutFront Pipe cover

Valve mountingbracket

Model RAV- SP240

Power supply 208/230 V, 60 Hz

MCA 24 A

MOCP (MAX Fuse/CB) 40 A

Breaker 25 A

System interconnection wires AWG12

MCA = Minimum Circuit AmpsMOCP =Maximum Over Protection Device Amps.

L1

L2

L1

L2

S

L1

L2

S

Inputpower

(Field powersupply)

(Systeminterconnection wires)

ground

Outdoor unit Indoor unit

Remotecontroller

circuit breaker

208/230 V~,60 Hz

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Wiring1. Remove the front panel and remove the front pipe

cover.

2. Remove the wire cover from back of the front pipe

cover.

3. Pass the wires through the conduit connection holes

and attach the conduit connecters.

4. Connect the wires to the terminal blocks and fix the

wires to the wiring guide with the 2 included banding

band.

L1 L2L1 L2 S

Field power supplyterminal block

Field powersupply wires

Ground screw

Systeminterconncectionterminal block

Ground screw

Banding band

Systeminterconnectionwires

Remove the 4screws.

Front pipe cover

Cable coverWire cover

Conduit connector

Terminal block

Do not make thewires slack in thissection.

Fix with the 2banding band.

Wire guide

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5. Pass the wires through the wiring guide of the front

pipe cover and adjust the wire lengths.

6. Attach the wire cover and hold the wires with the

wiring guide hooks.Do not clip or damage the wires with the cover.

7. Attach the front pipe cover with 4 screws.

8. Connect 2 conduits.

Wiring guide

Fix with a screw.

Hook

Wire cover

Fix with 4screws

conduit

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8 EVACUATE AND DEHYDRATE THESYSTEM

CAUTION

UNIT DAMAGE HAZARDFailure to follow this caution may result in equipmentdamage or improper operation.Never use the system compressor as a vacuum pump.

Refrigerant tubes and indoor heat exchanger should

be evacuated using the recommended deep vacuum

method of 500 microns. The alternate triple evacuation

method may be used if the procedure outlined below is

followed. Always break a vacuum with dry nitrogen.

SYSTEM VACUUM ANDCHARGE

Using Vacuum Pump

1. Completely tighten flare nuts A, B, C, D, connect

manifold gage charge hose to a charge port of the

low side service valve.

2. Connect charge hose to vacuum pump.

3. Fully open the low side of manifold gage.

4. Start vacuum pump.5. Evacuate using either deep vacuum or triple

evacuation method.

6. After evacuation is complete, fully close the low sideof manifold gage and stop operation of vacuum

pump.

Deep Vacuum Method

The deep vacuum method requires a vacuum pump

capable of pulling a vacuum of 500 microns and a

vacuum gage capable of accurately measuring this

vacuum depth. The deep vacuum method is the most

positive way of assuring a system is free of air and

liquid water.

Triple Evacuation Method

The triple evacuation method should only be used

when vacuum pump is only capable of pumping down

to 28 in. of mercury vacuum and system does not

contain any liquid water.

Refer to Triple Evacuation Method chart and proceed

as follows:

1. Pump system down to 28 in. of mercury and allow

pump to continue operating for an additional 15minutes.

2. Close service valves and shut off vacuum pump.

3. Connect a nitrogen cylinder and regulator to system

and open until system pressure is 2 psig.

4. Close service valve and allow system to stand for 1

hr. During this time, dry nitrogen will be able to

diffuse throughout the system absorbing moisture.

5. Repeat this procedure as indicated in the chart.

System will then be free of any cotaminants and

water vapor.

Service Valve

Indoor UnitC

D

A

B

RefrigerantLow Side

High Side

Outdoor Unit

Service Valve

Manifold

500 microns

Manifold Gage

Low side valve

Charge hose

High side valve

Charge hose

Vacuum pump

Low side valve

500

0

1000

1500

2000

2500

3000

3500

4000

4500

5000

1 2 3 4 5 6 7

LEAK IN

SYSTEM

VACUUM TIGHT

TOO WET

TIGHT DRY

SYSTEM

Deep Vacuum Graph

MICRONS

MINUTES

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Triple Evacuation Method chart

Final Tubing Check

IMPORTANT:

Check to be certain factory tubing on both indoor and

outdoor unit has not shifted during shipment. Ensure

tubes are not rubbing against each other or any sheet

metal. Pay close attention to feeder rubes, making surewire ties on feeder tubes are secure and tight.

Open service valves

Open or close the valve.

Liquid side

Open the valve with a 4 mm hexagon wrench.

Gas side

While the valve is fully opened, after the screwdriver

has reached the stopper, do not apply torque

exceeding 4 ftlbs (5 Nm). Applying excessive

torque may damage the valve.

Valve handling precautions

Open the valve stem until it reaches the stop.

It is unnecessary to apply further force.

Securely tighten the cap with a torque wrench. Cap tightening torque

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

CHECK FOR TIGHT, DRY SYSTEM(IF IT HOLDS DEEP VACCUM)

RELEASE CHARGE INTO SYSTEM

Valve size3/8 (9.5 mm) 24 - 31 ftlbs (33 - 42 Nm)

5/8 (15.9 mm) 15 - 18 ftlbs (20 - 25 Nm)

Charge port 10 - 13 ftlbs (14 - 18 Nm)

Valve unit

Charge orifice

Using a straight bladescrewdriver, turn it 90counter clockwise untilthe valve is fully open(against the stop).

Flare nut

Handle position

Fully closed Fully opened

Stop pin

Main stopper

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9 FINISHINGAfter the refrigerant pipe, inter-unit wires, and drain pipe have been connected, make sure they are supported and

fixed in place for the entire length.

Keep the power wires and system interconnection wires away from all factory wiring and piping.

10TEST RUN Turn on the circuit breaker at least 12 hours before starting the system to preheat the compressor and

prevent damage.

To protect the compressor, power is supplied from the 208/230 VAC input to the unit to preheat the compressor.

Check the following before starting a test run:

That all pipes are connected securely without leaks.

That the valve is open.

If the compressor is operated with the valve closed, the outdoor unit will become over pressurized, which maydamage the compressor or other components.

If there is a leak at a connection, air can be sucked in and the internal pressure further increases, which may

cause a burst or injury.

Operate the air conditioner using the correct procedure as specified in the Owners Manual.

11PERIODIC MAINTENANCE For an air conditioning system that is operated on a regular basis, cleaning and maintenance of the indoor/

outdoor units are strongly recommended.

As a general rule, if an indoor unit is operated for about 8 hours daily, the indoor/outdoor units will need to be

cleaned at least once every 3 months. This cleaning and maintenance should be carried out by a qualifiedservice person.

Failure to clean the indoor/outdoor units regularly will result in poor performance, icing, water leaking and even

compressor failure.

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12TROUBLESHOOTINGYou can perform fault diagnosis of the outdoor unit with the LEDs on the P.C. board of the outdoor unit in addition

to using the check codes displayed on the wired remote controller of the indoor unit.

Use the LEDs and check codes for various checks. Details of the check codes displayed on the wired remotecontroller of the indoor unit are described in the Installation Manual of the indoor unit.

Verifying Fault code status (Outdoor controlboard)

1. Check that DIP switch SW803 is set to off.

2. Record the states (on or off) of LED 800 to LED 804

(Display mode 1).

3. Press SW800 for at least 1 second. The LED status

changes to display mode 2.

4. Since display mode 1 covers multiple faults with the

same code display, mode 2 must also be used to

determine the final fault. Use the status recorded for

LED 800 to LED 804 in display mode 1 (Item 2

above) and combine it with the status for the same

LEDs in display mode 2 (Item 3 above) to determine

the complete fault code using the chart below.

Verifying Fault code status stored inmemory (Outdoor control board)

1. Check that DIP switch SW803 is set to on.

2. Record the states (on or off) of LED 800 to LED 804

(Display mode 1).

3. Press SW800 for at least 1 second. The LED status

changes to display mode 2.

4. Since display mode 1 covers multiple faults with the

same code display, mode 2 must also be used to

determine the final fault. Use the status recorded for

LED 800 to LED 804 in display mode 1 (Item 2

above) and combine it with the status for the same

LEDs in display mode 2 (Item 3 above) to determine

the complete fault code using the chart below.

NOTE

An outside air temperature (TO) sensor error can be

checked only when an error occurs.

No. CauseDisplay mode 1 Display mode 2

D800 D801 D802 D803 D804 D800 D801 D802 D803 D8041 Normal

2 Discharge (TD) sensor error { { {

3 Heat exchanger (TE) sensor error { { {

4 Heat exchanger (TL) sensor error { { {

5 Outside air temperature (TO) sensor error { { {

6 Suction (TS) sensor error { { {

7 Heat sink (TH) sensor error { { {

8Outdoor temperature sensor (TE/TS) connectionerror

{ { {

9 Outdoor EEPROM error { { {

10 Compressor lock { {

11 Compressor lock { {

12 Current detection circuit error { {

13 Thermostat for compressor activated { {

14Model data not set(on the service P.C. board) { { {

15 MCU-MCU communication error { { {

16 Discharge temperature error { { { {

17Abnormal power(open phase detected or abnormal voltage) { { { {

18 Heat sink overheat{ { { {

19 Gas leak detected { { { {

20 4-way valve reverse error { { { {

(:OFF {:ON :Flashing)

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* The LEDs and DIP switches are located on the lower left of the P.C. board of the outdoor unit.

21 High pressure release operation { { { {

22 Outdoor fan motor error { { { {

23 Compressor driver short-circuit protection { { { {

24 Position detection circuit error in one-line display { { { {

No. CauseDisplay mode 1 Display mode 2

D800 D801 D802 D803 D804 D800 D801 D802 D803 D804

(:OFF {:ON :Flashing)

SW801

SW804

SW800

LEDON 12

3

4

SW803

ON 1

2

3

4

SW802

ON 1

2

3

4

D800

D801

D802D803

D804

D805

D800

D801

D802D803

D804

D805

Enlarged viewof LEDs

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13UNIT PUMP DOWN Use the pump down switch SW801 on the P.C. board of the outdoor unit to pump down the unit.

Procedure1. Turn on the power of the air conditioner.

2. Select the FAN mode for indoor unit operation with the remote controller.

3. Set SW804 on the P.C. board of the outdoor unit to all OFF, and then press SW801 for 1 second or more. The

air conditioner enters the forced cooling mode for up to 10 minutes.

Pump down the unit during this 10 minutes.

4. Upon completion of pump down the unit, close the valve and press SW801 for at least 1 second to stop

operation.

5. Turn off the power.

DANGER

Be careful of electric shock because the P.C. board has an electrical current running through it.

14POWER SAVE Power save can be set by setting SW802 dip switch.

Procedure

1. Turn on the SW802 dip switch 2 to activate Power save.

Power save controls reducing compressor periodicity (by approx. 10%) depending on the indoor unit heatexchanger temperature in heating operation

* All switches are OFF as factory default.

CAUTION

Do not touch SW802 dip switch 1, 3 and 4.If any changes are made, the unit may not work properly.

Refrigerantrecovery switchSW801

Optionalconnector CN610

Special operationselect switchSW804

Existing pipeswitch SW802

P.C. boardPump downswitchSW801

Optional connectorCN610

Special operationselect switchSW804

Power save switchSW802

P.C. board

1

2

3

4

ON

SW802

... Power save setting

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installation manual eh99865401.pdf

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